Apparatus and methods for wedge lock prevention

ABSTRACT

In one embodiment, a tubular handling apparatus is provided with a wedge lock release mechanism that creates a clearance to allow movement by the mandrel having mating wedge surfaces relative to the tubular to release the wedge slips. In another embodiment, a tubular handling apparatus for handling a tubular includes a mandrel; a carrier coupled to the mandrel; a gripping element for engaging the tubular; an engagement member coupled to the carrier for engaging an upper portion of the tubular; and an abutment device adapted to engage the engagement member, wherein a length of the abutment device is adjustable to allow movement of the engagement member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent ApplicationSer. No. 61/050,121, filed on May 2, 2008; U.S. Provisional PatentApplication Ser. No. 61/126,223, filed on May 2, 2008; and U.S.Provisional Patent Application Ser. No. 61/126,301, filed on May 2,2008. Each of the above referenced patent applications is incorporatedherein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention relate to methods and apparatus forhandling tubulars using top drive systems. Particularly, the inventionrelates to methods and apparatus for engaging and disengaging a tubularhandling apparatus from a tubular. More particularly still, theinvention relates to a release mechanism for preventing the grippingelements of a tubular handling apparatus from locking during operations.

2. Description of the Related Art

It is known in the industry to use top drive systems to rotate a drillstring to form a borehole. Top drive systems are equipped with a motorto provide torque for rotating the drilling string. The quill of the topdrive is typically threadedly connected to an upper end of the drillpipe in order to transmit torque to the drill pipe. Top drives may alsobe used in a drilling with casing operation to rotate the casing.

In order to drill with casing, most existing top drives require athreaded crossover adapter to connect to the casing. This is because thequill of the top drives is not sized to connect with the threads of thecasing. The crossover adapter is design to alleviate this problem.Typically, one end of the crossover adapter is designed to connect withthe quill, while the other end is designed to connect with the casing.

In some instances, a tubular handling apparatus having movable grippingelements can be connected below the top drive to grip a tubular, such ascasing, so that the tubular handling apparatus and the tubular may bedriven axially or rotationally by the top drive. The tubular handlingapparatus may be referred to as internal or external gripping toolsdepending on whether the tool grips an internal or external surface ofthe tubular.

Some of the tubular handling apparatus may use wedge type slips to gripthe tubular. In the case of an internal gripping tool, the wedge slipsare moved downward along a mating wedge surface to urge the wedge slipsradially outward into contact with the interior surface of the tubular.To increase the gripping force on the tubular, the wedge slips may beprovided with teeth on the gripping surface. Generally, the teeth arearranged to point up in order to prevent the tubular from sliding down.This arrangement allows the teeth to “bite” into the tubular in responseto the weight of the tubular.

There is a need, therefore, for methods and apparatus for ensuringeffective release of the wedge slips from the tubular.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide apparatus and methods forpreventing or resolving a wedge lock condition. In one embodiment, thetubular handling apparatus is provided with a wedge lock releasemechanism that creates a clearance to allow movement by the mandrelhaving mating wedge surfaces relative to the tubular to release thewedge slips.

In one embodiment, a release apparatus for releasing a gripping elementof a tubular handling apparatus includes an anchor attached to thetubular handling apparatus; an engagement member for engaging thetubular; and an abutment device disposed between the anchor and theengagement member, wherein a distance between the anchor and theabutment device is adjustable to allow axial movement of the engagementmember. In another embodiment, the abutment device is adjustablerelative to the tubular gripping apparatus.

In another embodiment, a tubular handling apparatus for handling atubular includes a mandrel; a carrier coupled to the mandrel; a grippingelement for engaging the tubular; an engagement member for engaging anupper portion of the tubular; and an abutment device adapted to limittravel of the engagement member, wherein a length of the abutment deviceis adjustable to allow movement of the engagement member. In yet anotherembodiment, the tubular handling apparatus includes an anchor attachedto the carrier. In yet another embodiment, the abutment device isadjustable relative to the anchor.

In another embodiment, a method of releasing from a wedge lock conditionduring a tubular handling operation includes providing a tubularhandling apparatus having a mandrel, a gripping element movable alongthe mandrel, and an engagement member for contacting a tubular andattaching a release mechanism to the mandrel, wherein the releasemechanism includes an anchor and an abutment device axially movablerelative to the anchor. The method also includes engaging the tubular tothe engagement member and the engagement member to the abutment device;moving the abutment device away from the tubular; moving the mandrelrelative to the engagement member; and releasing the gripping element.

In another embodiment, a release apparatus for releasing a grippingelement of a tubular handling apparatus includes an anchor attached tothe tubular handling apparatus and an engagement member for engaging thetubular, wherein the position of the engagement member relative to theanchor is selectively adjustable to allow for relative axial movementbetween the anchor and the tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 is a cross-sectional view of an exemplary internal gripping tool.

FIG. 2 is an enlarged view of an exemplary hydraulic actuator.

FIG. 3 shows an exemplary wedge lock release mechanism using a heightadjustable stop member.

FIG. 4 shows the wedge lock release mechanism of FIG. 3 during normaloperations.

FIG. 5 shows the wedge lock release mechanism of FIG. 3 activated toresolve a wedge lock condition.

FIGS. 6A-6C illustrates another embodiment of a wedge lock releasemechanism having a tapered ring. FIG. 6A is a perspective view of thewedge lock release mechanism.

FIG. 6B shows the wedge lock release mechanism of FIG. 6A during normaloperations.

FIG. 6 c shows the wedge lock release mechanism of FIG. 6A activated toresolve a wedge lock condition.

FIGS. 7A-C illustrate another embodiment of a wedge lock releasemechanism having a ball ring. FIG. 7A is a perspective view of the wedgelock release mechanism.

FIGS. 7B and 7B1 show the wedge lock release mechanism of FIG. 7A duringnormal operations.

FIGS. 7C and 7C1 show the wedge lock release mechanism of FIG. 7Aactivated to resolve a wedge lock condition.

FIGS. 7D and 7D1 show another embodiment of a wedge lock releasemechanism during normal operations.

FIGS. 7E and 7E1 show the wedge lock release mechanism of FIG. 7Dactivated to resolve a wedge lock condition.

FIGS. 8A-8E illustrate another embodiment of a wedge lock releasemechanism having an eccentric bolt. FIG. 8A is a perspective view of thewedge lock release mechanism.

FIG. 8B shows the wedge lock release mechanism of FIG. 8A during normaloperations.

FIG. 8C shows the wedge lock release mechanism of FIG. 8A activated toresolve a wedge lock condition.

FIG. 8D is a perspective view of a bolt of the wedge lock releasemechanism of FIG. 8A. FIG. 8E is a front view of the bolt of FIG. 8D.

FIG. 9A shows another embodiment of a wedge lock release mechanism ofduring normal operations.

FIG. 9B shows the wedge lock release mechanism of FIG. 9A activated toresolve a wedge lock condition.

FIG. 10A shows another embodiment of a wedge lock release mechanism ofduring normal operations.

FIG. 10B shows the wedge lock release mechanism of FIG. 10A activated toresolve a wedge lock condition.

FIGS. 11A-11D illustrate another embodiment of a wedge release mechanismusable with an external gripping tool. FIG. 11A shows the externalgripping tool in an unclamped position. FIG. 11B shows the externalgripping tool in a clamped position. FIG. 11C shows the externalgripping tool applying a downward force on the tubular. FIG. 11D showsan embodiment of a thread compensator.

FIG. 12 shows another embodiment of a tubular handling apparatus.

FIG. 13 shows another embodiment of a wedge lock release mechanisminstalled on the tubular handling apparatus of FIG. 12.

FIG. 14 is a partial perspective view of the tubular handling apparatusof FIG. 12.

FIG. 15 is a partial exploded view of FIG. 14.

FIGS. 16-19 are partial exploded views of the tubular handling apparatusin operation. FIG. 16 shows the tubular handling apparatus being lowereduntil the bumper plate engages the casing. FIG. 17 shows the tubularhandling apparatus being lowered further. FIG. 18 shows the mandrelrelative to the carrier after the lowering of the tubular handlingapparatus has stopped. FIG. 19 shows the mandrel is contacting thebumper plate.

FIG. 20 shows the wedge lock release mechanism of FIG. 13 in theunreleased position.

FIG. 21 shows the wedge lock release mechanism of FIG. 13 in thereleased position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Tubular handling apparatus may use wedge type slips to grip the tubular.To release the tubular, the wedge slips are retracted along the matingwedge surface to urge the wedge slips radially inward. However, theretraction may cause teeth on the wedge slips to bite into the tubularbecause the wedge slips are pulled in direction of the teeth. Therefore,it is often desired to move the mandrel containing mating wedge surfaceslightly downward relative to the tubular before retracting the wedgeslips.

A problem may arise when the tubular handling apparatus is equipped witha coupling engagement member such as an engagement plate. In some cases,the engagement plate is fixed to the mandrel of the gripping tool tolimit the depth of the insertion of the internal gripping tool into thetubular. If the coupling abuts the engagement plate, the mandrel can nolonger be moved downward to facilitate the release of the wedge slips.The wedge slips are thus locked from release.

Embodiments of the present invention generally relate to a releasemechanism for preventing the gripping elements of a tubular handlingapparatus from locking during operations. In all embodiments, the toolsdescribed herein may be connected to a top drive, such that rotation ofthe top drive rotates the tool and the tubulars that are gripped by thetool. To better understand the novelty of the system of the presentinvention and the methods of use thereof, reference is hereafter made tothe accompanying drawings.

FIG. 1 is a cross-sectional view of an exemplary internal gripping tool100. The internal gripping tool includes the mandrel 110, grippingelements 155, and a hydraulic actuator 160 for actuating the grippingelements 155. As shown, the gripping elements 155 are wedge type slipsdisposed on a mating wedge surface of the mandrel 110. Axial movement ofthe slips relative to the mandrel 110 urges the slips to move radiallyoutward or inward. The internal gripping tool 100 may optionally beequipped with a fill-up tool 158.

FIG. 2 is an enlarged view of an exemplary hydraulic actuator 160. Theactuator 160 includes a housing 162 having a threaded connection to themandrel 110. The housing 162 may also be secured to the mandrel 110using a spline connection 161. One or more actuator cylinders 164attached to the housing 162 using bolts 163 are coupled to an actuatorpipe 165. The actuator pipe 165 is connected to the gripping elements155. Activation of the actuator cylinder 164 urges the axial movement ofthe actuator pipe 165. In turn, the actuator pipe 165 moves the grippingelements 155 relative to the mandrel 110. A coupling engagement plate170 (also referred to as a “Bumper Plate”) may be coupled to thehydraulic actuator 160. Contact with the casing coupling may cause axialmovement of the engagement plate 170. A stop member 178 is provided tolimit the travel of the engagement plate 170. Although embodiments ofthe wedge lock release mechanism will be discussed with reference to theinternal gripping tool, it is contemplated that the wedge lock releasemechanisms are suitable for use with an external gripping tool.Exemplary suitable internal or external gripping tools are disclosed inU.S. patent application Ser. No. ______, filed on May 5, 2009, entitled“Tubular Handling Apparatus” by M. Liess, et al., under attorney docketno. WEAT/0883, which application is incorporated herein by reference inits entirety.

FIG. 3 shows an exemplary wedge lock release mechanism using a heightadjustable stop member. As shown, the mandrel 110 and the grippingelements 155 are disposed in the tubular 102 and the gripping elements155 have been actuated into engagement with the tubular 102. In thisposition, the actuator pipe 165 has extended the gripping elements 155along the mating wedge surfaces of the mandrel 110, thereby extendingthe gripping elements 155 radially outward into engagement with tubular102. A stop member 178 is connected to an anchor 310 for attachment tothe mandrel 110. Alternatively, the anchor 310 may be attached to thehousing 162 of the hydraulic actuator 160, which in turn is attached tothe mandrel 110. In FIGS. 3-5, the stop member 178 is a screw that isattached to the anchor 310. The screw has a first length extending fromthe anchor 310. The engagement plate 170 is positioned at a distanceaway from the end of the stop member 178 and is movable relative to thestop member 178. In one embodiment, the engagement plate 170 is biasedaway from the anchor 310 using a biasing member such as a spring. Asshown, the coupling 101 of the tubular 102 is in contact with theengagement plate 170. The clearance between the engagement plate 170 andthe stop member 178 exists under standard operating conditions. Theclearance allows the mandrel 110 to move relative to the grippingelements 155 to release the gripping elements 155.

In some instances, it may be desirable to apply a downward force on thetubular 102. Application of this force may cause the mandrel 110 and thewedge slips to slide down relative to the tubular 102. This relativemovement causes the stop member 178 to contact engagement plate 170,thereby eliminating the clearance, as illustrated in FIG. 4. As aresult, the mandrel 110 is prevented from moving downward relative tothe tubular 102, and thus, locking the gripping elements 155 fromrelease.

When this condition occurs, the stop member 178 may be adjusted tocreate a clearance. As shown in FIG. 5, the screw may be released toadjust the height of the screw extending from the anchor 310. Forexample, the screw may be rotated to retract from the engagement plate170. In this respect, a clearance is created to allow the mandrel 110 tomove axially relative to the tubular 102 to facilitate the release ofthe gripping elements 155. In another embodiment, stop member may be abolt, pin, a retractable elongated member, or other suitable heightadjustable stop member. It is also contemplated that the stop member isremovable. In this respect, if the wedge lock condition occurs, the stopmember may be removed to create the clearance.

FIGS. 6A-6C illustrates another embodiment of a wedge lock releasemechanism 320. In this embodiment, the wedge lock release mechanism 320has a ring shaped anchor 321 attached to the mandrel 110 using a splineconnection. The anchor 321 may be secured to the mandrel 110 usingradially inserted pins or screws. The tubular coupling engagement member323 is also ring shaped and is coupled to the anchor 321 using a guiderod 324. The guide rod 324 allows the engagement member 323 to moveaxially relative to the anchor 321. A tapered ring 325 is disposedbetween the engagement member 323 and the anchor 321. The upper andlower contact surfaces of the tapered ring 325 have alternating tapersthat mate with complementary taper surfaces on the anchor 321 and theengagement member 323. Each taper may have a crest 327 and a recess 326.FIG. 6B shows the release mechanism 320 at normal operating height. Thecrest 327 of the tapered ring 325 is engaged with a corresponding crest327 of the anchor 321 or the engagement plate 323.

FIG. 6B presents a wedge lock condition in which the coupling 101 iscontacting the engagement member 323. In turn, the engagement member 323is in contact with the tapered ring 325, which is in contact with theanchor 321. In this respect, a clearance does not exist to allow themandrel 110 to move relative to the coupling 101, and thus, presenting awedge lock condition. To release the wedge lock, the tapered ring 325may be rotated, in this embodiment, to the left of the anchor 321 andthe engagement member 323, such that the crest 327 of the taper surfaceof the tapered ring 325 mates with a corresponding recess 326 of thetaper surface on the anchor 321 or the engagement member 323, as shownin FIG. 6C. In this respect, the overall height of the release mechanism320 may be reduced, thereby creating the clearance for movement of themandrel 110 to release the gripping elements 155. In another embodiment,the release mechanism 320 has an anchor coupled directly to theengagement member. The height of the release mechanism is adjustable byrotating either the anchor or the engagement member. In yet anotherembodiment, the tapered ring only one tapered surface for engagementwith the anchor 321 or the engagement member 323.

FIGS. 7A-C illustrate another embodiment of a wedge lock releasemechanism 330. In this embodiment, the wedge lock release mechanism 330has a ring shaped anchor 331 attached to the mandrel 110 using a splineconnection. The anchor 331 may be secured to the mandrel 110 usingradially inserted pins or screws. The coupling engagement member 333 isalso ring shaped and is coupled to the anchor 331 using a guide rod 334.The guide rod 334 allows the engagement member 333 to move axiallyrelative to the anchor 331. A ball ring 335 is disposed between theengagement member 333 and the anchor 331. A first set of balls 337 maybe disposed between the engagement member 333 and the ball ring 335 tofacilitate relative movement therebetween. A lower groove 338 forretaining the balls may be formed on the engagement member 333 and/orthe ring 335. A second set of balls 337 may be disposed between theanchor 321 and the ring 335. The upper groove 336 on the ball ring 335may be segmented such that each segment 336 is retaining one ball. Eachgroove segment 336 may have a pocket 332 disposed at an end of thegroove segment 336. The pocket 332 is recessed from the groove segment336 such that a ball in the pocket 332 is at a lower height than a ballin the groove segment 336. The anchor 331 may have a circular groove forinteracting with the balls 337 in the groove segment 336. FIGS. 7B and7B1 show the release mechanism 330 under normal operating height. Asshown, the balls 337 between the ball ring 335 and the anchor 321 aredisposed in the groove segment 336, not the pocket 332.

FIG. 7B presents a wedge lock condition in which the coupling 101 iscontacting the engagement member 333. In turn, the engagement member 333is in contact with the ball ring 335, which is in contact with theanchor 331 via the balls 337. In this respect, a clearance does notexist to allow the mandrel 110 to move relative to the coupling 101. Torelease the wedge lock, the ball ring 335 may be rotated, in thisembodiment, to the left, such that the balls 337 between the ring 325and the anchor 321 are moved from the groove segment 336 and disposed inone or more pockets 332, as shown in FIGS. 7C and 7C1. With the balls337 sitting in the pocket 332, the overall height of the releasemechanism 330 is reduced, thereby creating the clearance for movement ofthe mandrel 110 to release the gripping elements 155. In addition oralternatively, groove segments may be formed between the ball ring 335and the engagement member 333.

FIGS. 7D and 7D1 show another embodiment of the wedge lock releasemechanism. The release mechanism may include a spring 338 adapted topush the ball 337 out of the pocket 332, thereby returning the ball 337to the top position on the groove segment 336. FIGS. 7D and 7D1 show theball 337 in the groove segment 337 and the spring 338 in the extendedposition. FIG. 7D also presents a wedge lock condition. To resolve thewedge lock condition, the ball ring 335 is rotated to move the balls 337into the pocket 332. As seen in FIGS. 7E and 7E1, the balls 337 aresitting in the pocket 332 and have compressed the spring 338, therebyreducing the height of the release mechanism. The decrease in heightcreates a clearance between engagement member 333 and the coupling 101to facilitate the release of the gripping elements.

FIGS. 8A-D illustrate another embodiment of a wedge lock releasemechanism 340. In this embodiment, the wedge lock release mechanism 340has a ring shaped anchor 341 attached to the mandrel 110 using a splineconnection. The anchor 341 may be secured to the mandrel 110 usingradially inserted pins or screws. A coupling engagement member 343 isalso ring shaped and is coupled to the anchor 341 using a guide rod 344.The guide rod 344 allows the engagement member 343 to move axiallyrelative to the anchor 341. A plurality of eccentric bolts 345 arerotatably coupled to the anchor 341. Each bolt 345 has a first end and asecond end rotatably coupled to the anchor 341 and may act as axles forthe bolt 345. The body 348 between the two ends has an eccentriccross-section. In one embodiment, the body 348 has a firstcross-sectional thickness 346 that is greater than a second thickness347, as illustrated in FIG. 8E. As shown, the body 348 has an arcuateshape that extends over 180 degrees. The two ends of the arcuate shapedare connected by a flat surface. During normal operations, the bolt 345is positioned such that the longer first thickness 346 is aligned withthe axis of the tubular and that the dimension of the first thickness347 is selected so that a lower end of the first thickness 346 extendsbelow the anchor 341, as illustrated in FIG. 8B. In this respect, theengagement member 343 would contact the bolt 345 instead of the anchor341, thereby providing a clearance between the anchor 341 and theengagement member 343. The dimension of the shorter second thickness 347may be selected such that when the bolt 345 is rotated to move theshorter second thickness 347 in axial alignment with the tubular, theengagement member 343 may directly contact the anchor 341, asillustrated in FIG. 8C.

FIG. 8B presents a wedge lock condition in which the coupling 101 is incontact with the engagement member 343. As show, the coupling 101 is incontact with the engagement member 343, which is in contact with thebolt 345. A clearance does not exist to allow the mandrel 110 to moverelative to the coupling 101. To release the wedge lock, the bolts 345may be rotated such that the shorter second side is in the axialposition. In this embodiment, the bolts 345 are rotated such that theflat surface is facing the engagement member 343, as shown in FIG. 8C.In this respect, the engagement member 343 is allowed to move closertoward the anchor 341, thereby reducing the overall height of therelease mechanism 340. In this manner, a clearance between theengagement member 343 and the coupling 101 may be created for movementof the mandrel 110 to release the wedge.

FIGS. 9A-9B illustrate another embodiment of a wedge release mechanism.In this embodiment, the wedge lock release mechanism is a piston andcylinder assembly 350 attached to the mandrel 110. The piston 351 isattached to the anchor 352, and the cylinder 354 is attached to theengagement plate 353. Alternatively, the lower portion of the cylindermay act as the engagement plate. A fluid path 355 exists to introduce orrelease a fluid in the fluid chamber of the cylinder 354. In oneembodiment, the fluid path 355 may be connected to the release line 356of the cylinder 164. As shown in FIG. 9A, the cylinder 354 is in theextended position and is locked by a check valve 357. A clearance is notpresent to allow the release of the gripping elements 155. To releasethe wedge lock, fluid in the cylinder 354 is relieved through the checkvalve 357. This allows the cylinder 354 and the engagement plate 353 tomove upward to provide a clearance to release the gripping elements 155,as shown in FIG. 9B. It can be seen in FIG. 9B that the fluid chamberhas decreased in size. In another embodiment, the check valve 357 may beopened by the release of the clamping cylinders 164. Initially, theclamping cylinder is released to retract the gripping elements 155 andtubular 102 against the engagement plate 353. Because fluid path 355 isin communication with the release line 356, the pressure inside therelease line 356 opens the check valve 357. It is contemplated that oneor more piston and cylinder assemblies may be positioned around themandrel. It is also contemplated that the cylinder may be an annularcylinder around the mandrel. It is further contemplated the cylinder isattached to the anchor and the piston is attached to the engagementplate.

FIGS. 10A-10B illustrate another embodiment of a wedge releasemechanism. In this embodiment, the wedge lock release mechanism is apiston and cylinder assembly 360 attached to the mandrel 110. The piston361 is attached to the anchor 362, and the cylinder 364 is attached tothe engagement plate 363. The assembly 360 includes an extension fluidpath 365 for extending the cylinder 364 and a retraction fluid path 366for retracting the cylinder 364. As shown in FIG. 10A, the cylinder 354is in the extended position and a clearance between the engagement plate363 and the coupling of the tubular 102 is not present to allow therelease of the gripping elements 155. To release the wedge lock, fluidis supplied through the retraction fluid path 366, and the extensionfluid path 365 is opened. This operation will lift the cylinder 364 uprelative to the piston 361 to provide clearance to release the grippingelements 155, as shown in FIG. 10B. To return to the extended position,fluid is supplied through the extension fluid path 365 and theretraction fluid path 366 is opened. It is contemplated that one or morepiston and cylinder assemblies may be positioned around the mandrel. Itis also contemplated that the cylinder may be an annular cylinder aroundthe mandrel. It is further contemplated the cylinder is attached to theanchor and the piston is attached to the engagement plate.

FIGS. 11A-11D illustrate another embodiment of a wedge release mechanismusable with an external gripping tool 200. The external gripping tool200 includes the mandrel 110 coupled to a carrier 250. The mandrel 110has a load collar 252 which can engage an interior shoulder 254 of thecarrier 250. The mandrel 110 may have a polygonal cross-section such asa square for transferring torque to the carrier 250. The externalgripping tool 200 also includes a plurality of gripping elements 255 anda hydraulic actuator 260 for actuating the gripping elements 255. Thehydraulic actuator 260 may be attached to the carrier 250 using athreaded connection. In one embodiment, the gripping elements 255 areslips disposed in the carrier 250. Actuation of the hydraulic actuator260 causes axial movement of the slips relative to the carrier 250. Thegripping elements 255 have wedged shaped back surfaces that engage wedgeshaped inner surfaces of the carrier 250. In this respect, axialmovement of the gripping elements 255 relative to the wedge surfaces ofthe carrier 250 causes radial movement of the gripping elements.

A thread compensator 220 may be used to couple the carrier 250 to themandrel 110. In FIG. 11D, the thread compensator is a spring threadcompensator 220 that allows the carrier 250 and its attachments to floatindependent of the mandrel 110. In one embodiment, the compensator 220includes a nut 221 threadedly attached to the exterior of the mandrel110 and a base plate 222 attached to the mandrel 110. In this respect,the nut 221 and the base plate 222 are fixed relative to the mandrel110. A cover 223 is provided above the base plate 222 and around the nut221 to support a plurality of pins 224 that extend through apertures inthe base plate 222. Compression springs 225 are disposed around each pin224 and between the upper portion of the cover 223 and the base plate222. In this respect, the springs 225 may exert a biasing force betweenthe cover 223 and the base plate 222. Because the base plate 222 isfixed to the mandrel 110, the cover 223 is free to move up and downrelative to the base plate 222 as dictated by the springs 225. Themovement of the cover 223 is also referred to herein as floatingrelative to the base plate 222 or mandrel 110. The end of the pins 224protruding from the base plate 222 is connected to the carrier 250. Thepins 224 may be connected to the carrier 250 using a threadedconnection. The pins 224 allow the carrier 250 to move with the cover223 in accordance with the biasing force applied by the springs 225. Itshould be noted that the springs may be replaced with hydraulic pistons.

Referring to FIG. 11A, the carrier 250 is supported by the load collar252 of the mandrel 110. The wedge slips 255 are in the retractedposition. The tubular is positioned in the carrier 250 such that thecoupling 101 is in contact with the engagement plate 270. A gap existsbetween the load collar 252 and the engagement plate 270. In FIG. 11B,the clamping cylinders 260 are actuated to extend the gripping elements255 into engagement with the tubular 102. The gripping elements 255 areurged inwardly by the corresponding wedge surfaces of the carrier 250.As shown, the relative position of the engagement plate 270 and themandrel 110 has not changed. If a pushing force is desired, the mandrel110 will lower down relative to the carrier 250 and come into contactwith the engagement plate 270 to place load directly on the tubular 102.FIG. 11C shows the mandrel 110 in contact with the engagement plate 270.In this position, a gap now exists between the load collar 252 and theshoulder 254 of the carrier 250. The presence of the gap prevents thewedge lock condition from occurring. In one embodiment, the threadcompensator 220 will lift the carrier 250 up from the mandrel 110,thereby creating a clearance between the mandrel 110 and the carrier250. The clearance provides the spacing required for the release of thegripping elements 255.

For operations involving applying a pushing force, the external grippingtool 200 should be lowered over the tubular 102 until a couplingindicator indicates that the coupling 101 has been reached. Then, thegripping elements 255 may be applied to grip the tubular 102. Theconnection is then made up. Thereafter, the external gripping tool 200is lowered until the mandrel 110 reaches the coupling, and the pushforce may now be applied.

FIG. 12 shows an exemplary tubular handling apparatus 600 having amandrel 610 coupled to a carrier 650. A swivel 605 is disposed above themandrel 610. A link support housing 613 of a link assembly 108 isattached to the mandrel 610 above the swivel 605, and a threadcompensator 520 is attached to the link support housing 613. In oneembodiment, the tubular handling apparatus may be equipped with a torquemeasuring device. The torque measuring device includes a torque shaftrotationally coupled to the top drive, a strain gage disposed on thetorque shaft for measuring a torque exerted on the torque shaft by thetop drive, and an antenna in communication with the strain gage. Asshown, the tubular handling apparatus 600 has gripped the tubular 601using gripping elements 255 such as slips. The slips are actuated by ahydraulic actuator 620 that moves the slips axially relative to thecarrier 650. The tubular 101 is in contact with an engagement plate 670,which is disposed below the load collar 611 of the mandrel 610. Afill-up and circulation tool 658 may be installed on the tubularhandling apparatus 600.

FIG. 13 shows a partial view of another embodiment of a wedge lockrelease mechanism 620 installed on the tubular handling apparatus. Thetubular handling apparatus is shown with the mandrel 610 supporting thecarrier 650. The bumper plate 670 is positioned inside the carrier 650for engagement with the tubular. Engagement with the tubular may causethe bumper plate 670 to move axially relative to the carrier 650. In oneembodiment, the bumper plate 670 is coupled to the carrier 650 usingguiding elements 675 that are movable in a slot 655 of the carrier 650.

The release mechanism 620 acts as a stop member for limiting the upwardmovement of the guiding elements 655 and the bumper plate 670. In oneembodiment, the release mechanism 620 includes an anchor 622 attached tothe carrier 650. The anchor 622 may be attached using welding or othersuitable methods of attachment. In another embodiment, the anchor 622and the carrier 650 may be formed from one piece of steel or othersuitable material. An engagement member 624 is coupled to the anchor 622using a connection device 626 such as a screw. The engagement member 624has a wedge surface that is movable along a wedge surface of the anchor622. Movement of the engagement member 624 is controlled by releasingthe screw 626. An optional rubber bumper 628 releasably attached to theengagement member 624 may be provided for engagement with the guidingelement 675. The rubber bumper 628 may be exchanged as it wears downfrom use.

The tubular handling apparatus may optionally include a couplingdetection system for indicating presence of a coupling. The couplingdetection system includes a coupling indicator 632 connected to theguiding elements. The coupling indicator 632 may be an elongated memberhaving tapered portions to indicate the position of the tubularcoupling. A lower end of the coupling indicator 632 is connected to thecoupling engagement plate 670 and movable therewith. In one embodiment,the coupling indicator 632 has an upper narrow portion and a lower wideportion to indicate the absence or presence of the coupling. A sensor635 may be adapted to read the coupling indicator 632 to determine thepresence or absence of the coupling in a similar manner as the sensor175. FIG. 14 shows the position of the indicator 632 when the guidingelement is contacting the rubber bumper 628. FIG. 15 is a partialexploded view of FIG. 14.

FIGS. 16-19 are partial exploded views of the tubular handling apparatusin operation. In FIG. 16, the tubular handling apparatus has beenlowered until the bumper plate 670 engages the casing 601. In oneembodiment, the tubular handling apparatus is lowered with the threadcompensator 520 activated. In this respect, a substantial portion of theweight of the carrier is borne by the thread compensator 520, while theremainder is borne by the shoulder of the mandrel 610. The threadcompensator 520 may hold at least 85% of the weight; preferably, atleast 95%. As shown, the bumper plate 670 is at the lower end of theslot 655 and has not engaged the release mechanism 620. In thisposition, further lowering of the apparatus will lower the carrier 650relative to the bumper plate 670, which is resting on top of the casing601.

FIG. 17 shows the tubular handling apparatus being lowered further. Thecarrier 650 has moved relative to the bumper plate 670, thereby causingthe guiding elements 675 to engage rubber bumper 628 of the releasemechanism 620. In this position, further lowering of the apparatus willlower the mandrel 610 relative to the carrier 650. Also, a substantialportion of the weight of the carrier continues to be borne by the threadcompensator 520, while the remainder is now borne by the bumper plate670. The thread compensator 520 may hold at least 85% of the weight;preferably, at least 95%. In addition, the coupling indicator 632 hasmoved up with the bumper plate 670, which movement is detected by thesensor 635.

FIG. 18 shows the mandrel 610 relative to the carrier 650 after thelowering of the tubular handling apparatus has stopped and inanticipation of the thread compensation. As shown, the mandrel 610 isnot in contact with the bumper plate 670. The distance between the loadshoulder of the mandrel 610 and the shoulder of the carrier 650 may beused for thread compensation. In one embodiment, a sensor may beprovided to measure the optimal distance (i.e., the minimal distancerequired for thread compensation) has been reached. In anotherembodiment, a sensor may be provided to warn the distance isinsufficient to avoid contact of the mandrel 610 with the bumper plate670.

FIG. 19 shows the situation where the mandrel 610 is contacting thebumper plate 670. This may occur after the casing has been made up andwhen a push force is applied to the casing string using the tubularhandling apparatus. This position allows axial force to be applied tothe casing string without loading the gripping elements.

When the situation shown in FIG. 19 occurs, the carrier 650 cannot moveupward to release the gripping elements. This situation may be referredas a “wedge lock” condition. To remedy this situation, the screw 626 maybe released from the anchor 622. FIG. 20 shows the screw 626 in theunreleased position. FIG. 21 shows the screw 626 in the releasedposition. As the screw 626 is released from the anchor 622, theengagement member 624 is moved along the wedge surface and away from theguiding elements 675, thereby creating a space 660 between the rubberbumper 628 and guiding elements 675. The space 660 allows the carrier650 to move axially relative to the gripping elements, thereby releasingthe gripping elements from the casing.

Actuation of each mechanism described herein may be manual, hydraulic,pneumatic or electric. Actuation may further be initiated locally at thetool or remotely from a control panel. Furthermore, actuation may betriggered automatically by a control command to release the slips. Inall embodiments, the devices may be reset to their original positionsafter the slips have been released from the tubular.

In all embodiments, the devices may be reset to their original positionsafter the slips have been released from the tubular. Resetting may bemanual, hydraulic, pneumatic or electric. Resetting may further beinitiated locally at the tool or remotely from a control panel.Furthermore, Resetting may be triggered automatically by a controlcommand, for example to engage the slips. In all embodiments, thedevices may be reset to their original positions after the slips havebeen released from the tubular.

In addition to casing, aspects of the present invention are equallysuited to handle tubulars such as drill pipe, tubing, and other types oftubulars known to a person of ordinary skill in the art. Moreover, thetubular handling operations contemplated herein may include connectionand disconnection of tubulars as well as running in or pulling outtubulars from the well.

In another embodiment, a release apparatus for releasing a grippingelement of a tubular handling apparatus includes an anchor attached tothe tubular handling apparatus and an engagement member for engaging thetubular, wherein the position of the engagement member relative to theanchor is selectively adjustable to allow for relative axial movementbetween the anchor and the tubular. In yet another embodiment, therelease apparatus is configured to be manually actuated or remotelyactuated. In yet another embodiment, the release apparatus is configuredto be hydraulically actuated, pneumatically actuated, electricallyactuated, and combinations thereof. In yet another embodiment, therelease apparatus is configured to be resettable.

In one embodiment, a release apparatus for releasing a gripping elementof a tubular handling apparatus includes an anchor attached to thetubular handling apparatus; an engagement member for engaging thetubular; and an abutment device disposed between the anchor and theengagement member, wherein a length of the abutment device is adjustablerelative to the anchor.

In another embodiment, a tubular handling apparatus for handling atubular includes a mandrel; a carrier coupled to the mandrel; a grippingelement for engaging the tubular; an engagement member coupled to thecarrier for engaging an upper portion of the tubular; and an abutmentdevice adapted to engage the engagement member, wherein a length of theabutment device is adjustable to allow movement of the engagementmember. Further, the length of the abutment device may be adjustedmanually or by remote actuation.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A release apparatus for releasing a gripping element of a tubularhandling apparatus, comprising: an anchor attached to the tubularhandling apparatus; an engagement member for engaging the tubular; andan abutment device disposed between the anchor and the engagementmember, wherein a distance between the anchor and the abutment device isadjustable to allow axial movement of the engagement member.
 2. Theapparatus of claim 1, wherein the abutment device is adjustable relativeto the tubular gripping apparatus.
 3. The apparatus of claim 1, whereinthe abutment device comprises a tapered ring.
 4. The apparatus of claim3, wherein the tapered ring is disposed between the anchor and theengagement member and the tapered ring is rotatable to adjust thedistance between the tapered ring and the anchor.
 5. The apparatus ofclaim 1, wherein the abutment device comprises an eccentric bolt.
 6. Theapparatus of claim 5, wherein the eccentric bolt has a first widthlonger than a second width and the bolt is rotatable from the firstwidth to the second width to adjust the distance between the anchor andthe engagement member.
 7. The apparatus of claim 1, wherein the abutmentdevice comprises a ball ring.
 8. The apparatus of claim 7, wherein theball ring is disposed between the anchor and the engagement member,wherein rotation of the ball ring adjusts the distance between theanchor and the ball ring.
 9. The apparatus of claim 1, wherein theabutment device comprises a piston and cylinder assembly.
 10. Theapparatus of claim 1, wherein the abutment device comprises a screw. 11.A tubular handling apparatus for handling a tubular, comprising: amandrel; a carrier coupled to the mandrel; a gripping element forengaging the tubular; an engagement member for engaging an upper portionof the tubular; and an abutment device adapted to limit travel of theengagement member, wherein a length of the abutment device is adjustableto allow movement of the engagement member.
 12. The apparatus of claim11, further comprising an anchor attached to the carrier.
 13. Theapparatus of claim 12, wherein the abutment device is adjustablerelative to the anchor.
 14. The apparatus of claim 11, furthercomprising an thread compensator.
 15. A method of releasing from a wedgelock condition during a tubular handling operation, comprising:providing a tubular handling apparatus having a mandrel, a grippingelement movable along the mandrel, and an engagement member forcontacting a tubular; attaching a release mechanism to the mandrel,wherein the release mechanism includes an anchor and an abutment deviceaxially movable relative to the anchor; engaging the tubular to theengagement member and the engagement member to the abutment device;moving the abutment device away from the tubular; moving the mandrelrelative to the engagement member; and releasing the gripping element.16. The method of claim 15, wherein moving the abutment device away fromthe tubular comprises rotating the abutment device.
 17. The method ofclaim 15, further comprising coupling an indicator to the engagementmember.
 18. The method of claim 15, linking operation of the releasemechanism to the operation of a clamping cylinder.
 19. A releaseapparatus for releasing a gripping element of a tubular handlingapparatus, comprising: an anchor attached to the tubular handlingapparatus; and an engagement member for engaging the tubular, whereinthe position of the engagement member relative to the anchor isselectively adjustable to allow for relative axial movement between theanchor and the tubular.
 20. The release apparatus of claim 19, whereinthe release apparatus is configured to be manually actuated or remotelyactuated.
 21. The release apparatus of claim 19, wherein the releaseapparatus is configured to be hydraulically actuated, pneumaticallyactuated, electrically actuated, and combinations thereof.
 22. Therelease apparatus of claim 19, wherein the release apparatus isconfigured to be resettable.